Apparatus for and methods of making a sheet metal strip structure



June 16, 1964 A. J. UNGERER 3,

APPARATUS FOR AND METHODS OF MAKING A SHEET METAL STRIP STRUCTURE 6 Sheets-Sheet 1 Filed March 11, 1960 INVENTOR. AARON .z UNGERER A TTOR/VEYJ June 16, 1964 7 3 w 7 3 3 m E w A m mm m m R R fl G P N I N .8 JL M m APPARATUS FOR AND METHODS OF 6 Sheets-Sheet 2 Filed March 11, 1960 INVENTOR. AARON .I UA/GERER ATTORNEYS A. J. UNGERER ons OF June 16, 1964 3,137,337

APPARATUS FOR AND METH MAKING A SHEET METAL STRIP STRUCTURE 6 Sheets-Sheet 3 Filed March 11, 1960 INVENTOR. AARON J. UA/GERER BY 77/5,, 15/4, ii. 5

14 TTORNE Y5 June 16, 1964 A. J. UNGERER 3,137,337

APPARATUS FOR AND METHODS OF MAKING A SHEET METAL STRIP STRUCTURE Filed March 11, 1960 6 Sheets-Sheet 4 .1. E j INVENTOR.

AARON J. UNGERER BY W, M, nflm 1% A T TOR/V5 Y5 June 16, 1964 A. J. UNGERER 3,137,337

APPARATUS FOR AND METHODS OF MAKING A SHEET METAL STRIP STRUCTURE Filed March 11, 1960 6 Sheets-Sheet 5 INVEN TOR. AARON J UNGERER A TTURIVE Y5 June 16, 1964 A. J. UNGERER APPARATUS FOR AND METHODS OF MAKING A SHEET METAL STRIP STRUCTURE 6 Sheets-Sheet 6 Filed March 11, 1960 m m M AARo/v J U/VGERER A TTOR/VEYS United States Patent 3,137,337 v APPARATUS FUR AND METHODS OF MAKING SHEET METAL STRIP STRUCTURE Aaron J. Ungerer, Lakewood, Ohio, assignor to The Standard Products Company, Cleveiand, Ohio, a corporation of Ohio Filed Mar. 11, 1960, Ser. No. 14,433 Claims. (Cl. 153-2) said -.-sections along said 'path and for stacking said sections in successive partially overlapped relation to each I other and in such manner that the sections disposedon vanced along a Working path and divided into divisions or sections longitudinally therealong and whereby adjacent strip sections are arranged in a progressive overlapping relation to each other and which are angularly disposed relative to the longitudinal axis of said structure.

Another object of the present invention is the provision of a new and novel method for fabricating a sheet metal strip structure as referred to in the last preceding para graph and wherein the overlapping strip sectionsare flattened while in said angular position to thus define said structure in a substantially flat configuration.

Still another object of the present invention is the provision of a new and novel method and to apparatus for practicing the said method for use in the manufacture of a flexible sheet metal strip structure and wherein said apparatus includes means for longitudinally dividing a sheet metal strip into successively arranged and substantially equal divisions or sections andfor advancing said divided strip along a working path, and means for arranging adjacent sections of said strip in a progressive partially overlapping relation to each other wherein each of said section is angularly disposed relative to the longitudinal axis of said structure.

Another object of the present invention relates to a new and 'novel method for fabricating a flexible sheet metal strip structure wherein a sheet metal strip is ad- 1 vanced along a working path and divided into substantially equal divisions or sections disposed longitudinally therealong, and wherein adjacent sections are arranged in progressive partially overlapping relation to each other with each of said sections being angularly disposed relative to the longitudinal axis of said structure, and at a complementary angle from said axis with respect to the next adjacent strip section. v

Still another object of the present invention relates to opposite ends of any one section are arrange'din substantial parallel spaced relation to each other'and partially overlap opposite surfaces of said interspaced strip section, Additional objects and advantages of the new and novel method'and apparatus of the present invention will be readily apparent to one skilled in the'art to which this inventionpertains, and by reference to the following disclosure of a preferred embodiment thereof and as is illustrated in the accompanying drawings, wherein:

FIG. 1 is a plan view of a preferred embodiment of apparatus embodying the inventive concepts of the present invention;

FIG. 2 is a fragmentary ing head of the apparatus assembly of FIG. 1;

FIG. 3 is an exploded perspective view of the mandrels V of the forming head of FIG. 2 with the. same removed from said head to clearly illustrate the function thereof;

FIG. 3A isa perspective view of the strip structure formed by the forminghead'of FIG. 3; FIG. 4 is a perspective View of the stacking head of the apparatus assembly of FIG. 1;

FIG. 5 is a side elevation of the barrel members of the stacking head of FIG. 4'with the sameremoved from I,

FIG. 9 is a fragmentary perspective view'of one of the 1 Q flattening rolls ofFIG. 8;

a new and novel method for fabricating a flexible sheet metal strip structure wherein a sheet metal strip is adf vanced along a working path and divided into substantially equal sections disposed longitudinally therealong,

and wherein adjacent sections are arranged in'progressive partially overlapping relation to each other in such 1 manner that each of the opposed surfaces of any one section is partially covered by one of the next adjoining sec tions to said one section.

Another object is to provide a new and improved apparatus for practicing the said method of the present in section, and means for flattening said stacked assembly to thus form the aforesaid flexible strip structure.

' FIG. 10 is a side elevation of the flattening head;

FIG. 11 isa sectionalview takenapproximately on the plane as is indicated by the line 1111'in FIG. 10; and,

FIG; 12 is a-plan view'of a portion of the flattened strip structure. v 3

The new and novel method of the p'res'entinvention is intended to accomplish a continuous fabrication of a flexible" sheet metal strip structure wherein a flat strip or ribbon of sheet metal is advanced along a predetermined working path, and divided longitudinally therealonginto'substantially equal divisions or sections by pro: jections, theoutennost portion or crest of each of which extends angularly across the width of the strip, the crest portions of 'adjacent projectionsi'bing disposedin substantialparallel spaced relation, and further wherein the aforesaid divisions or sections are arranged. or stacked in progre'ssive partially overlapped relation to each other Withsaid crest portions defining the lateral edges of 'the stacked assembly, and further wherein said; divisions or sections of said,assembly are flattened one againstthe other in said partially overlapped relation @to' thus form the aforesaid flexible strip structure. T I Thegaformentioned projections are preferably formed on the strip by progressively advancing the same through a forming head or station operable to sequentiallyfor'm a plurality ofthe aforesaid projections thereon which are; disposed inlpredetermined spaced relation longitudinally therealong, said projections preferably extending alter perspective view of the formnately in opposite directions from the plane of said strip and thus formed so that the outermost portion or crest of each of said projections extends angularly across the width of the strip.

With said projections thus formed thereon, the strip is then alternately folded along each of said crest portions,

the above defined divisions or sections-interspaced between said crest portions being thus stacked in a progressive partially overlapped relation along an axis that is substantially parallel to and equally spaced between said crest portions, alternate crest portions thus forming the opposed lateral edges of the stacked assembly.

Said stacked assembly is thereafter presented to flattening means functioning to flatten said assembly to form the aforementioned strip structure, said flattening means being likewise operable during the flattening of said assembly to maintain the partial overlapped relation between each of the aforementioned strip divisions or sections.

With reference now directed to the accompanying drawings, a preferred embodiment is herein shown of apparatus especially designed to practice the method of the present invention, and briefly consists of a forming head or station A adapted to receive a flat strip or ribbon of sheet metal and to advance the same along a working path, being operable to successively form a plurality of longitudinally spaced projections P thereon, said projections, as best seen in FIG. 3, extending outwardly from said strip with the outermost portion or crest a thereof extending angularly across the width of the strip and thus inclined relative to the lateral edges thereof, with alternate projections P extending outwardly in opposite directions from the plane of said strip.

As the strip is advanced along said working path and V discharged from the forming head A, it is then presented to a stacking head or station B as best seen in FIG. 4, which functions to progressively alternately stack the divisions or sections a! defined between the aforesaid projections in a progressive partially overlapped relation along an axis substantially parallel to and equally interspaced between the crest portions of said projections, said strip assembly, as exiting from the stacking head, being preferably somewhat bowed in lateral configuration.

As the stacked assembly is advanced along said working path and subsequently discharged from the stacking head B, it is thenpresented to a flattening head C, as seen in FIG. 7, which functions to flatten the slightly laterally bowed stacked strip assembly into a substantially flat strip structure, said flattening head being likewise operable during the flattening of said assembly to positively engage said assembly and to maintain the partial overlapped relation between each of the aforementioned strip divisions or sections a! thereof.

With particular reference now directed to FIGS. 1 and 2, the forming head A is seen to comprise a pair of cylindrical mandrels 3 and 4, each being mounted, respectively, upon a shaft member 5 and 6, the latter being rotatably supported within bearing blocks 5a and 6a, carried within a pedestal 7 in vertically spaced relation one to the other, said pedestal, in turn, being rigidly carried upon a base 8 which is preferably adjustably mounted upon a machine table or bed T, of a machine supporting frame F. Suitable guide blocks 10 may be attached to the opposed ends of the aforesaid pedestal base 8 as best seen in P16. 2, having leg parts 1011 underlying the aforementioned machine table T and thereby operable to retain and thus properly guide the adjustable movement of said base and supported pedestal longitudinally along the latter. An adjustment rod 11 is seen to be threaded at its one end, being disposed within an upright plate 12 carried on the aforementioned machine bed T, and its opposite end journalled within a pressure block 12a, the latter being attached to the aforesaid pedestal base 8. A handle 11a carried on said one end of said rod may be utilized to adjustably move said rod within the plate 12 to thus adjustably slidably move the pedestal 7 and forming mandrels 3 and 4 longitudi nally along said machine bed T, the purpose for which will be hereinafter described in detail.

Each of the shaft members 5 and 6 rigidly mounts a suitable Worm gear 13 adjacent said mandrel and which is adapted to be in mesh with a corresponding worm 14 formed on drive shaft 15, the latter being interspaced between said shaft members 5 and 6, and suitably rotatably supported within the aforementioned pedestal 7, being in addition drivably connected to a suitable source of power, later to be defined.

As previously mentioned, the'flat strip or ribbon of sheet metal, as is identified by the reference character S in FIG. 2, is intended to be presented to the forming head A, which then functions to successively form the aforementioned projections P thereon.

For this purpose, as is best seen in FIG. 3, each of the forming mandrels 3 and 4, comprises a pair of cylindrical hub members 24 and 25 mounted upon its respective shaft member 5, 6 in abutting relation one to the other, and which, in turn, mount a plurality of male and female die elements 17 and 18 respectively, on the opposed abutting faces thereof and which elements are preferably disposed in a predetermined radial spaced relation therearound.

Inasmuch as the construction of each forming mandrel 3 and 4 is preferably identical, a detailed description of only forming mandrel 3 will now be given with particular differences in structure and/or function, if any, existing therebetween, being also hereinafter specifically referred to.

With particular reference now directed to FIG. 3, it will be seen that the inner or abutting face 28 of hub element 25 is substantially fiat and rigidly mounts a plurality of the aforesaid female die elements 18 thereon, said die elements being disposed in equally radially spaced relation thereon, the present forming mandrel embodiment preferably using a series of 8 of said die elements which are held in position by and between pairs of substantially triangular-shaped anchor blocks 29, the latter, in turn, being preferably of such dimension so as to define an opening or recess 30 between adjacent blocks of adjoining pairs of said blocks. In addition, each of said die elements 18 is preferably disposed radially of its associated shaft and has a die cavity 18a provided on its outermost face.

The adjoining inner or abutting face 32 of the hub member 24 of each forming mandrel is formed with a plurality of radially projecting recesses or grooves 33,

said grooves being likewise disposed in equal radially spaced relation to each other. One of the aforementioned male die elements 17 is adapted to be disposed within each of the said grooves or recesses 33, although the instant embodiment of forming mandrel preferably utilizes a series of 8 of said female die elements and cooper-.

ating male die elements as will hereinafter be described R in detail, it is understood that the number of said die hub member and radially outwardly of its peripheral edge. With the hub member 25 mounted upon its associated shaft member, its companion hub member 24 is then placed upon said shaft and disposed in said abutting relation with the former, and in such manner that each of the male die elements 17 is disposed within one of the aforementioned recesses 30.

Each of the male die elements 17 is also preferably slightly smaller in its lateral dimension than its accommodating recess 30, to thus define a radial side clearance therebetween, as may be indicated by the reference character E. The hub member 24 is likewise preferably disposed on its supporting shaft so that its inner face 32 lies upon the side surface 18b of each of the aforesaid female die elements 18, each of the latter in turn, mounting a pin 34, which projects substantially perpendicularly outwardly from said die surface 18b and extends toward and into one of a plurality of circular recesses 35 formed on the adjoining inner or abutting face 32 of hub member 24. As best seen in FIG. 3, each of said recesses 35 is substantially larger in dimension than the pin 34 accommodated therein, the purpose for which will be hereinafter explained.

With this construction, it will now be seenthat in each assembly of forming mandrels 3 and 4, the hub members 24 and thereof, are disposed so as to position the male and female die elements 17 and 18 respectively, in the same radial plane with respect to its supporting shaft member, and in equal radially, spaced relation to each other with each of the male die elements 17 being interspaced centrally between adjacent female die elements 18.

As best seen in FIGS. 2 and 3, the forming mandrels 3 and 4 are each preferably rotatably supported within the aforementioned pedestal 7, insubstantial vertical spaced relation to each other, and, in addition are rotatably driven through the aforesaid drive shaft 15 in opposite directions to each other such that the male die elements 17 on the upper forming mandrel 3 cooperate with the female die elements 18 on the lowerforming mandrel 4 to form every other one of the aforementioned projections P on the sheet metal strip passing therebetween, and likewise the male die elements 17 onsaid lower forming mandrel 4 similarly cooperate with the femaledie elements 18 on the upper roll forming mandrel 3 to fabricate the next adjacent projection on said strip. In this manner therefore, the projections P are seen to extend alternately in opposite directions from the plane of the strip S, said cooperating die elements being likewise operable to advance said strip S along the aforementioned working path progressively through the forming head A while simultaneously forming said projections. f

A suitable guide block 38 carried on the aforesaid-pedestal 7 is preferably utilized to direct the sheet metal strip S between the rotating mandrels 3 and 4 and in position as to be properly engaged by said die elements.

As is previously mentioned, each of the male die elements 17 carried on hub member 24 is slightly smaller in its lateral dimension than its accommodating recess Eachadjustment bar has a pair ofset screws 45 threadably disposedtherein, and which are adapted to engage,

pin 44 opposed flats 45a provided on the portion of said projecting into the aforesaid aperture 43.

The pin 44 is somewhat smaller in diameter than its accommodating aperture 43 so'that upon selectively 1oosening one of said set screws and advancing the other into said bar, said pin 44 may be adjustably moved within said aperture to thereby rotatably move the hub member 24 about its supporting shaft and thus align the maledie' position to thereby facilitate the engagement and/ or disengagement of said cooperating die elements.

As is also previously mentioned, each of the afore-- said projections P is formed in such manner that'its crest portion a extends angularly across the width of the sheet metal strip S. With reference directed to FIG. 3a, this angle of inclinationfor said crest portion with respect to v a line substantially perpendicular to the longitudinal axisof said strip is identified by the reference character X, the

purpose for said angulation being hereinafter morefully apparent. a 1 v As the sheet metal strip or ribbon S is discharged from the forming head A, it is then presented to the afore:

. rected to FIGS. "4 to 6 inclusive, thestacking head B is provided in its companion hub member 25, thus providing upper barrel member 50 meshing with adrive gear 57 V carriedson' an idler shaft 58, the latter being'rotatably I,

tate the proper alignment of the aforementioned cooperating male and female die elements.

To provide for a manual adjustment to the hub member 24 of each formingmandrel, an adjustment bar, as is identified by the reference numeral 40, is seen to be mounted at its center upon each of the aforesaid shaftv members 5, 6 adjacent the outer face of the hub member 24, being securely fastened to said .shaft by means of in 41. Said adjustment bar is apertured, as indicated at V 43 adjacent its one end, and mounted thereat upon pin 44, the latter being securely anchored to the adjacent hub member 24 and preferably extending perpendicularly outwardly of said outer face thereof. 7

seen to include a pain of barrel members 50 .and 51-which are'disposed in parallel spaced relation toeach other preferably one above the other, said barrels'being rotatably supported at one end within an upstanding bracket 52 v rigidly mounted on the machine table or bed T, each of said barrels, in addition, mounting a suitable bearing 53 on its opposite end, the bearing for said upper barrel mounted within an upstanding block 56, the latter being carried on said machine bed, said barrel members being thus disposedin tandem-relationto the aforesaid forming head A and extending substantially longitudinally along said machine bed. 1

As best seen in FIGS. 1 and 4, each of said barrel members is provided with-la pinion 56, the pinion on supported between one of the aforementioned brackets 54 and bracket 52. The pinion 5 on the lower barrel '7 member 51 is likewise adapted. to mesh with a transfer gear 60 mounted onlthe opposite end of the" aforementioned shaft 15 for-,thegforming head A, said transfergear, in addition, being disposed. soas to mesh with and be driven by the drive gear 57:;- v.

i The opposite endof the idler shaft 58: is seen to mount a suitable sprocket 59 over. whichispa ssed an endless link chain 62,,saidfchain being likewise passed around a drivesprocket mounted onithe shaft 63 "of a suitable pr mary sourceof power such as electric motor 64.. Said motor is preferably supported in the aforementionedfsupporting' frame F below thespro cket 59 on' 7 said idler shaft 58. If desired-said link chain-62' may also be passed around an idler sprocket 62a 'of f'a suitable adjustable tensioning device 63a which is utilized to maintain said link chain substantially taut.

As best seen in FIG. 1, power may also be taken from the idler shaft 58 through a suitable sprocket and endless link chain drive as will be understood, being thus capable of actuating a lubricating pump device, as is identified by the reference numeral 58a.

With this construction, it will now be realized that upon the proper energization of said power source, energy is simultaneously transferred through the aforementioned idler shaft 58 and drive gear 57 to the connected gear train just described, so as to simultaneously rotatably energize the forming mandrels 3 and 4 of the forming head A and also the barrels 5t) and 51 at the stacking head or station B.

In this manner, therefore, as will be later defined in greater detail, the actuation of the forming head A and stacking head B may be synchronized with each other so as to provide a continuous fabrication of the sheet metal strip being presented thereto.

As the sheet metal strip is discharged from the forming head A, it is thereafter directed along said working path and between the barrel members 5% and 51, means being provided on the latter to engage with said strip whereby the sections d thereof are progressively stacked in partial overlapping relation to each other.

For this purpose, as may be best seen in FIG. 5, each of the barrel members is provided with a groove extending helically around the periphery thereof, the groove for the upper barrel member 50, as is identified by the reference numeral 65, originating at the right end of the same and having what is commonly referred to in the art as a left-hand lead. Said helical groove is also seen to progressively diminish in lead or pitch as it advances longitudinally along the aforementioned barrel member, being likewise of maximum lateral dimension in the area of maximum lead and progressively diminishing in said lateral dimension in a corresponding relation to the decrease in the aforesaid lead or pitch thereof.

The groove formed in the lower barrel member 51, as may be identified by the reference numeral 68, is substantially identical in configuration to the aforesaid groove 65 and likewise originates at the right end of said lower barrel member, extending helically around the periphery of the same and has what is commonly referred to in the art as a right-hand lead. The progressive reduction in the lead of each of said grooves 65 and 68 is preferably identical, as the same advances longitudinally from right to left along its associated barrel member, said barrel members, in addition, each being rotatably supported and thus connected to and locked into the above described gear train such that said grooves are substantially 180 degrees out of phase with each other. As will likewise be seen in FIG. 5, the lead of each groove 65 and 68 is preferably gradually decreased as the same advances along its respective barrel member to an intermediate region thereon, and is thereafter reduced at a substantially increased rate as the groove approaches the opposite or left end thereof. In addition, the lead of each of said grooves at the right end of its respective barrel member is intended to correspond to the angular inclination X of the crest portion of each of the aforementioned projections P.

It will also be seen upon reference to FIG. 5 that each of the barrelmembers 50 and 51 is gradually decreased in its diameter, beginning at its right end, to a minimum dimension at said intermediate region whereat said diameter is thereafter progressively increased toward the opposite or left end thereof. With this configuration therefore, it will be realized that the spacing between said barrel members and corresponding grooves likewise progressively increases to said region and then decreases in the same direction along said barrels or from right to left, as viewed in FIG. 5.

As before mentioned, the sheet metal strip is discharged from the forming head A in such manner that the projections P thereon preferably lie in substantially a vertical plane, said strip being thereafter intended to be presented to and between the barrel members 50 and 51 in a plane intersecting the axes of the same.

To accomplish this, a guide block 70 is attached to the aforesaid bearing block 56 and disposed so as to be substantially in longitudinal prolongation to said intersecting plane, said block in addition, having a channel "I1 formed centrally longitudinally therethrough and which communicates with said intersecting plane.

The strip 8 is placed within and moved through said channel and guided thereby centrally along said intersecting plane and into the aforesaid spacing whereby, as the barrel members are rotated, the crest portions 11 of the upwardly extending projections P are intended to successively enter into the right end of the helical groove 65 in the upper barrel 50, being hence captured therein, and in like manner, the crest portions a of the downwardly extending projections P are adapted to successively enter into the helical groove 68 in said lower barrel, beinglikewise captured therein. In this manner the strip sections 0? extending between adjoining projections P traversed the aforesaid spacing between said barrel members.

With this particular arrangement, it will now be'realized, as may be best seen in FIGS. 4 and S, that with the upper barrel member 50 being rotated in a clockwise direction and the lower barrel member 51 simultaneously rotatable in a counterclockwise direction so as to advance the corresponding helical grooves 65 and 68 formed thereon from right to left with respect to the aforesaid intersecting plane, the sheet metal strip captured therebetween will likewise be moved or advanced thereby from right to left longitudinally along said barrel members.

And, as the lead of the aforesaid grooves progressively decrease, as above described, it is also apparent that the distance said strip is advanced per each revolution of said barrel members also progressively decreases at a corresponding rate. Consequently, with any one strip section d being moved to the left at a progressively decreasing rate, the next succeeding section d of said strip is being advanced toward the latter at a somewhat increased rate due to the greater lead in said grooves at said latter barrel region. As a result the strip sections d are pro gressively moved or stacked in juxtaposition to each other as said strip is moved longitudinally along and through 7 said intersecting plane.

As shown in FIG. 4, with the barrel members 50 and 51 being oppositely rotatable in the manner as above described, a component of force as indicated by the vector 1 is created thereby and applied to the metal strip disposed therebetween, which force tends to propel said strip laterally outwardly from between said barrel members.

To prevent this from occurring, the instant embodiment of stacking head B includes a guide block which is disposed adjacent one side of said barrel members, preferably extending longitudinally along the latter, and which is adjustably mountedupon support plates 77 and 78,

said plates, in turn, being carried upon the aforementioned bearing block 56.

The guide block 75 as may be best seen in FIGS. 4 and 6, is provided with a blade portion 75a of reduced thickness, extending longitudinally along one edge thereof, and which projects into the aforementioned spacing defined between the barrel members 50 and 51, said blade portion terminating in a guide surface 755 formed thereon and defining the opposite or inner longitudinal edge of said block, and which preferably lies closely adjacent to and on one side of the aforementioned plane intersecting the axes of said barrel members.

As best seen in FIG. 6, the guide surface 75b of said block and an adjoining surface 76a of a backing plate 76 disposed on the opposite side of the aforementioned barrel members and intersecting plane, being'suitably mounted on the machine bed T, define a continuation of the aforementioned working path through which the sheet metal strip is carried during the interval it is being fabricated by the instant stacking head B.

As the sheet metal strip is advanced along and between said barrel members, the aforesaid force exerted thereon by the latter is effective to press its one lateral edge against the guide surface 75b of said blade, and is thereby retained in said plane. I I

Adjacent the terminal end of each of said grooves 65 and 68, or at the left end of the barrel members 50 and 51, as seen in FIG. 5, the rate at which the lead thereof is reduced is substantially increased and is thus effective to bring adjoining divisions or sections d of said strip gized from a common powersource 64 and interconnected gear train, as above. described, to assure the proper into substantially close juxtaposition to each otherx The crest portions of said strip are likewise somewhat reduced in radial dimension to thus define the opposed sides of the collapsed sections of said strip.

Also adjacent said terminal end of the aforesaid barrel members the-guide block 75 is provided with a radius as is identified by the reference numeral 80, which connects at its one end with the aforementioned guide surface 75b, and extending from the latter forwardly and outwardly therefrom in the direction ofmovement of thelmaterial strip between said barrel members to terminate on the side of said. block opposite to said guidesurface to thus" define a curved extension of the same. As will be hereinafter explained in greater detail, the dimension ,of'the radius 80 is selected so that with a predetermined progressive reduction in the lead of the grooves 65, 68 of the barrel members 50, 51, the desire'doverlap'ping of the strip sections d may beobtained. v 1 If desired, a curved upstanding plate 77a may also be attached to the end of backing plate 76 adjacent said radius to thus define a substantially-laterally extendingdischarge path for the strip exiting-from the rotating barrel members 50 and EL: s

With this construction, as the sheet metal strip is carried through the aforesaid spacingbetween the barrel members 50 and 51, and enters into the region there between adjacent said curved radiusportion 80 of said,

block 75, the'aforementioned component of forceexerted by eachof said barrel members upon said strip is effective to push the latter intopositive engagementwith said radius portion.

As a result, the strip erally from between said barrel. members, each of'the strip sections d' being somewhat bowedlongitudinally therealong and progressively moved outwardly of said spacing. along said path in substantially a vertical plane,

said stripv sections being simultaneously stacked one upon is discharged. substantially lat- V the other with any one section being progressively moved along said lateral discharge path so that the next succeeding section is also advanced therealong -.-'and:-thus stacked in a partialoverlapping relation thereto to thus form the aforementioned stacked strip assembly.-

With said strip assembly being thus discharged-from the stacking head B, the aforesaid crest portions on opposite lateral edges of said assembly.

It will likewise be realized that. the strip sections are assembly.

' As previously mentioned, the pedestal 7 mountinglthe' fonnin'g-mandrels 3 and 4 of the forming head A isadjustable longitudinally along the machine bed" T toward and/ or away from the stacking head B." This particillar" 60. ends of each of said stripsections 01 define the opposed.

' of the flattened strip structure; I V

With reference now directed particularly to FIGS. 1

construction enables the forming mandrels 3.'and 4 toform the projections P in the sheet metal strip Sand to discharge the same from said forming head in proper phase relationship to the operation of the stacking head B whereby the projections P. onsaid strip are in proper position to be continuously successively picked up and captured within the grooves of: the barrel members and 51'o f saidstacking head. i

As is also previously mentioned, the forming head A and stacking head B are preferably simultaneously enercooperative operation 'therebetween.

, As the stacked assembly ofsheet metal strip is dis charged from the. stacking head B it is next presented to the flattening head or station '0 ofthe instant machine structurewherein its'lateral somewhat bowed configuration' is flattened, with a predetermined partial overlapped relation between each of said sections being established and with the aforementioned. crest. portions. a of the projections .P defining the. opposed lateralparallel edges and 7, the instant embodiment of flattening head C is seen to .inclu de a rectangular mounting plate 82which is preferably mounted at its ends by means of angles 83 to a right-angle extension-of supporting frame F, said plate extending vertically" upwardly above 1 said supporting frame, and preferably located adjacent the discharge end of'the stacking 'head' B;

,ya-A suitable speed ratio unit, asidentified in its entirety by thereferencenumeral 65, is likewise mounted on the- 1 right'angle trarnewextension, its input shaft d'mounting a sprocket 66- about which is passedjan endless-link chain 66a, said chainllikewise passing around a seconddrive sprocket 66b carried onv the aforementioned shaft of the motor 64. As will bepresently described, the speed'ratio unit 165' *is 'interconnected between the aforesaid motor 64 andthe instant flattening head- C, being thus operable" to ptpvide for a suitable transfer of power therebetween which @is 'etfectiveto actuate saidhead. .1

. A pairkciffiatteningrolls, as identified by the reference,

numeralst84 and 85, are eachni'ountedupon a spindle 86; 87. respectively, each ofsaid spindles being rotatably supported atone end within-the aforementioned mountf ing-plate 82 and at the opposite end'fwithin a tie bar 8411 in such mannersasto-locate 'said flatteningfroll s substan tially xvertically one above the other in predetermined spaced relation. t

- The spindle 86 is preferably adjustable'within its.

mountingsupports by means of adjusting studs 85a to" thus/selectively move'its flatteningroll 84*into 'apre f-f' selected spacedrelation with'the bottom roll 85- to therebydefine a flattening plane adapted to accommodateraipar 1 tic ul arvthickness of stacked strip assembly, 1 I

' A 'drive 'shaft"8 8,'-'.asj best seen F IG I-I, su'itably "jour naled' withina bearing'block 89carriedfon the'aforesaid mounting platei '82 is seen to have'asprocket90 carried" on jits'. one end 'overnwhich spams-an endless-chain. 91,.the latter likewise passing around a drive sprocket 92Ionl thezoutput'shaft" 93 of theaforementioned{speed 'ffThefopposite end of said drive,shaftj88, as best'fseen 5 in FIGSQTand 10, mountsadrivegeart94vwhich is 'in I j t tendedQtomesh 'ith' anidle'r gear' QS cai'ried' on thej'ad Y jacentend of-jan idler shaft 96, the latter 'bein'gfsuitamy journaled within the mountingplate' s2. Said-idler gear;

95,-inturn,meshe's with gear 97 mounted-on thejafore W said spindle 87 being thus etfective to rotatably 'drivethe 3 latterandbottom flattening"roll likemianner, 1 transfer ear 98' 'carriedron ha'ft- 99"jofurnaled' in plate 82; 1 I

" a end e shaft'l102 'likewise 'QP-I i h s :82, eii s se "ms na it ig ar 103.;carried on' the spindle 86," being; thus effective to' Y is adapted-to mesh-x ,7 aforesaid idler? gearj 1 01gsimilarly carried on a 1 1 provide for rotatably actuating the upper flattening roll 84.

With this construction, it will now be realized that each of the aforesaid forming heads of the instant machine assembly is actuated in substantial synchronized relation to each other, forming heads A and B being simultaneously actuated by electric motor 64 through the idler shaft 58 and connected gear train as above described, and forming head C by means of the aforementioned speedratio unit 65 connecting with said motor and drive shaft 88 of said flattening head C. In this manner therefore, a continuous fabrication of the flexible sheet metal strip structure may be readily obtained, as will hereinafter be more fully realized.

As best seen in FIG. 7, the stacked assembly of sheet metal strip is intended to be passed between the flattening rolls 84, 85, the latter being thus operable to flatten the same in the manner as is above mentioned.

To properly guide the stacked strip assembly to and between said rolls, the instant form of flattening head C also includes a curved guide chute 105, its one end being connected by means of fasteners 106 to the lower end of an upwardly inclined guide plate 108, said chute extending outwardly and downwardly from said connected end to terminate preferably in substantially a vertical plane.

Said inclined guide plate 108, adjacent its opposite end, is preferably attached to the underside of a Wear plate 109, said wear plate, in turn, mounting a pin 110 which is slidably adjustably disposed Within a slot 112 formed in said mounting plate 82. Said guide plate and adjacent end of said chute is thus adapted to be adjustably moved vertically along said mounting plate 82 to thus locate the same in proper position to present the stacked strip assembly along an upwardly inclined path to and between the aforesaid flattening rolls, the purpose for which will be presently explained.

As the stacked assembly of sheet metal strip is passed between the flattening rolls 84 and 85, means are provided on the same to maintain a preselected spacing between each of the partially overlapped strip sections a.

For this purpose, as may be best seen in FIGS. 8 and 9, the lower flattening roll 85 is preferably formed with a plurality of notches 113 disposed in equally spaced relation around each of its opposed peripheral edges, the notches on one edge being centrally interspaced or' staggered between the notches on the opposite edge of said roll, the preferred peripheral spacing between each of said notches on one edge and the next adjacent notch on the opposite edge being identified in FIG. 9 by the reference character Y. As best seen in FIGS. 7 and 8, the stacked strip assembly,'as discharged from the stacking head B, is presented to and between said flattening rolls while being supported in an upwardly inclined plane by the aforementioned chute 105 and connected guide plate 108. The endkof the guide plate 108 is preferably disposed closely adjacent the flattening rolls 84 and 85, and slightly below the flattening plane thereof so that the strip assembly drapes over a small peripheral partof the surface of said bottom roll prior to its being presented to and passed through said plane. v e

In this manner, as best seen in FIG. 8, each of the aforementioned opposed edges e and e" of several ormore i of said strip sections d may be disposed within one of the spaced notches 113 on said bottom roll, and thus remain insaid capture d position while said .strip sections are successively passed through said plane and flattened by said rolls. r

A pair of disks 115, as best seen in FIG. 7, may be placed over the opposed sides of the bottom flattening roll 85, preferably being'of such'diameter as to partially encase-the lower portion-of the upper roll 84, being thereby effective to keepthe strip assembly directly between said rolls and in the aforesaid flattening plane during the flattening thereof.

12 I As will be understood, with particular reference directed to FIG. 8, the flattening action of the aforesaid rolls 84 and 85 have a tendency to cause a reduction in the angular overlapping relation between adjoining strip sections d of the strip assembly, said relationship being identified in FIG. 4 by the reference character u.

As is also viewed in FIG. 12, the desired angular relationship or lead angle between adjoining strip sections of the flattened strip structure as discharged from the flattening head C. is seen to be identified by the reference character R. I a a The angular relationship between adjoined strip sections d of the stacked strip'as'sembly, as discharged from the stacking head B, identified above by the reference character a, may likewise vary slightly within preselected manufacturing tolerances as will be understood, the preferred magnitude therefor being slightly greater than the magnitude of the lead angle R, and as determined by the combined effects of the selected angular inclination X of the crest portion of each projection P, the progressive reduction in the lead of the helical grooves 65 and 68 of the barrel members 50 and 51, respectively, and the dimension of the radius portion in the guide block 75.

With the above dimensional relationship in mind, the peripheral spacing Y between the notches on the opposed edges of the bottom flattening roll is therefore selected to correspond to the linear distance, measured along the axis of the flattened strip structure as shown in FIG. 12, between the opposite ends of each of the strip sections d, said linear distance being identified by the reference character n.

With this particular construction, it will now be realized that as the stacked strip'assembly is presented and passed through the flattening plane between said rolls 84 and 85 and flattened thereby, the opposite ends of the leading edge of each strip section d disposed in the aforementioned adjacent notches on opposed sides of said bottom roll encounter the front vertical edge of eachof said notches and said strip section d in its flattened cona flatsheet metal strip is advanced along a working path a and divided into substantially equal sections, which sections are each arranged in partial overlapping relation to each other 'in a stacked assembly, said sections being angularly disposed relative to the longitudinal axis of said assembly and thereafter flattened to thus provide a flat, flexible sheet metal strip structure. 1 Y i It will also be realizedby one skilled in the 'art'to which the present inventionpertains that the novel' apparatus disclosed herein and which is especially designed. to practice the method of the present invention'is susceptible to various modifications, combinations and. arrange ments of the parts without departing from the scope of the inventive concepts thereof 'as are defined in the claims;

1. An apparatus for making a flexible sheet metal strip structure, means foradvancing a sheetjmetal strip along a predetermined path, means for forming a plurality of projections along said strip to divide said strip into sections extending longitudinally therealong, said pm jections extending alternately in oppositerdirectionsfrom the plane of said strip, andmeansfor successively engaging said projections being effective to progressively stack overlapping relation to each other.

adjacent strip sections extending therebetween in' partial,

2. An apparatus for making a flexible sheet metal strip a predetermined path, means for forming a plurality of projections along said strip to divide the same into sections extending longitudinally therealong, said projections extending completely across said strip and inclined in the direction of travel of said strip, andmeans for stacking said strip along said projections to dispose adjacent sections at said inclined position and in partial overlapping relation to each other wherein adjacent projections define opposed lateral edges of the stacked strip assembly.

3. An apparatus for making a flexible sheet metal strip structure, means for advancing a sheet metal strip along a predetermined path, means for forming a plurality of projections along said strip to divide the same into sections extending longitudinally therealong, said projections extending completely across said strip and alternately in opposite directions from the plane thereof being inclined in the direction of travel of said strip, means for stacking said strip along said projections to dispose adjacent sections at said inclined'position and in partial overlapping relation to each other to form a stacked strip assembly, and means for flattening said assembly wherein alternate projections define opposed lateral edges of the flattened strip structure.

4. An apparatus for making'a flexible sheet metal strip structure, means for advancing a sheet metal strip along a a predetermined path including a pair of forming mandrels disposed on opposite sides of said path and actuatable to move said strip along said path, means on said mauclrels responsive to the actuation of the same to form a plurality of projections along said strip and divide the same into sections extending longitudinally therealong, and means for stacking said strip along adjacent projections to dispose adjacent sections of said strip in partialover lapping relation to each other.

5. An apparatus for making a flexible sheet metal strip structure, means for advancing a sheet metal strip along a predetermined path including a pair of forming mandrels disposed on opposite sides of said strip and rotatable in a plane intersecting said path, die means on said mandrels responsive to the rotatable actuation of the same and carried thereby into said path so as to successively form a plurality of projections along said stripand divide said strip into sections extending longitudinally therealong,

for stacking said strip along adjacent projections to dispose adjacent sections of said strip relation to each other.

6. An apparatus for making a flexible sheet metal strip structure as defined in claim and wherein said die means includes at least one pair of cooperating male and female die elements responsive to the actuation of the forming mandrels to successively form a plurality of projections on said sheet metal strip.

7. An apparatus for making a flexible sheet metal strip structure as is defined in claim 6 and wherein the cooperating die elements are adjustable about the rotatable axis or" the forming mandrels.

8. An apparatus for making a flexible sheet metal strip structure, means for advancing a sheet metal strip along a predetermined path, means for forming a plurality of projections along said strip to divide said strip into sections extending longitudinally therealong, said projections extending alternately in opposite directions from said projections extending alternately in opposite direction from the plane of'said strip, and means in partial overlapping the plane of said strip, means for stacking said strip sections including a pair ofbarrel members disposed on opposite sides of said strip and extending along said path, means on said barrel members engaging with said projec tions and operable in response to the rotation of said barrel members to progressively carry said projections along said path effective to alternately stack adjacent strip sections in partial overlapping relation-to each other to thus form a stacked strip assembly wherein alternate projections define the lateral edges of the stacked strip assembly.

9. An apparatus for making a'flexible sheet metalstrip structure, means for advancing a sheet metal strip,

along a predetermined path, means for forming aplurality of projections along said strip to divide said strip into sections extending longitudinally therealong, said projections extending alternately in opposite directions from the plane of said strip, means for stacking strip sections including a pair. of barrel members disposed in spaced relation to each other on opposite sides of said strip and extending along said path, a helical groove formed on the periphery of each barrel member being of opposite lead relative to each other and progressively decreasing in said lead in the direction of movement of said strip along said path, said strip advancing along said path and passing centrally between said barrel members and along a plane interposed between the latter, said grooves being operable in response to the rotatable actuation of said barrel members to successively engage with said projections and carry the same and said strip progressively along said plane, said barrel members being operable at a portion therein wherein said grooves have a minimum lead to propel said strip laterally of said plane being ef- =fective to alternately stack adjacent strip sections in partial overlapping relation to each other to thus form a stacked strip assembly wherein alternate projections define the lateral edges of the stacked strip assembly.

10. An apparatus for making a flexible sheet metal strip structure, means for advancing a sheetmetal strip along a predetermined path, means for forming a plurality of projections along said strip to divide the same into sections extending longitudinally therealong, said projections extending completely across said strip and alternately in opposite directions from the plane thereof being inclinedin the-directionof travel of said strip, means for stacking said strip along said projection-s to dispose adjacent strip sections in partial overlapping relation to each other to form a stacked strip assembly wherein alternate projections define the opposed lateral edges of said assembly, and means for. flattening said assembly includ- 'ing a pair of flattening rolls disposed so as to permit said strip assembly to be passed therebetween, said rollsbeing rotatable to flatten said assembly wherein said alternate projections define the opposed lateral edges of the flattened strip structure.

1 References Cited in the file of this patent UNITED STATES PATENTS 'Great Britain July 30, 1892 

1. AN APPARATUS FOR MAKING A FLEXIBLE SHEET METAL STRIP STRUCTURE, MEANS FOR ADVANCING A SHEET METAL STRIP ALONG A PREDETERMINED PATH, MEANS FOR FORMING A PLURALITY OF PROJECTIONS ALONG SAID STRIP TO DIVIDE SAID STRIP INTO SECTIONS EXTENDING LONGITUDINALLY THEREALONG, SAID PROJECTIONS EXTENDING ALTERNATELY IN OPPOSITE DIRECTIONS FROM THE PLANE OF SAID STRIP, AND MEANS FOR SUCCESSIVELY ENGAGING SAID PROJECTIONS BEING EFFECTIVE TO PROGRESSIVELY STACK ADJACENT STRIP SECTIONS EXTENDING THEREBETWEEN IN PARTIAL OVERLAPPING RELATION TO EACH OTHER. 